Ion generator device

ABSTRACT

A system and method of treating air. Bipolar ionization is delivered to an airflow within a conduit from a tubeless ion generator. The ionized airflow may be delivered to a conditioned airspace by an HVAC system. In alternate applications, the airflow delivers ionized combustion air to an engine. The invention also includes a mounting assembly for positioning one or more ion generators into an airflow.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/105,110 filed Oct. 14, 2008, and U.S.Provisional Patent Application Ser. No. 61/221,763 filed Jun. 30, 2009,the entireties of which are hereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to the field of air treatment,and more particularly to the treatment of air using bipolar ionization.

BACKGROUND

Air and other fluids are commonly treated and delivered for a variety ofapplications. For example, in heating, ventilation and air-conditioning(HVAC) applications, air may be heated, cooled, humidified,dehumidified, filtered or otherwise treated for delivery intoresidential, commercial or other spaces.

In automotive and other engine applications, combustion air is filteredand mixed with fuel for delivery to the engine intake. Combustion air isalso filtered and delivered to the intake of oil and gas burners, forexample in heating and electrical generation applications.

Needs exist for improved systems and methods of treating and deliveringair for these and other applications. It is to the provision of improvedsystems and methods meeting these needs that the present invention isprimarily directed.

SUMMARY

In example embodiments, the present invention provides improved systemsand methods of treating and delivering air, for example in HVAC andcombustion air applications, through the application of bipolarionization to an airflow. In representative forms, the invention mayimprove efficiency and performance, for example providing improved fuelmileage, greater power output, reduced emissions, reduced particulates,and/or other benefits.

In one aspect, the present invention relates to a system for treatmentof an airflow within a conduit. The system includes at least one bipolarion generator having first and second electrodes, the first electrodegenerating positive ions and the second electrode generating negativeions. The first and second electrodes are aligned generallyperpendicular to the airflow within the conduit whereby at least aportion of the positive ions and the negative ions do not recombinewithin the airflow.

In another aspect, the invention relates to a combustion systemincluding a combustion air intake for delivering combustion air along aflowpath; and at least one bipolar ion generator for delivering positiveand negative ions into the combustion air. Each bipolar ion generatorhas positive and negative electrodes, the positive and negativeelectrodes being aligned generally crosswise relative to the flowpath ofthe combustion air.

In still another aspect, the invention relates to an HVAC systemincluding a shared outdoor heat exchanger and a plurality of individualair handler unit housings connected to the shared outdoor heat exchangerfor delivery of individual airflows through each of the individual airhandler unit housings. The system further includes at least one tubelessbipolar ion generator for delivering ions to the individual airflowsthrough each of the individual air handler unit housings.

In another aspect, the invention relates to a method of treatment of anairflow within a conduit. The method includes the steps of providing atleast one bipolar ion generator having first and second electrodes fordelivery of positive and negative ions within the conduit, and aligningthe first and second electrodes generally perpendicularly to the airflowwithin the conduit whereby at least a portion of the positive ions andthe negative ions do not recombine within the airflow.

In another aspect, the invention relates to a mounting assembly forapplication of bipolar ionization to an airflow within a conduit. Themounting assembly preferably includes an enclosure for mounting to theconduit, and an arm extending from the enclosure for extension into theconduit. At least one ion generator is coupled to the arm, the iongenerator having a pair of electrodes and being positioned on the armsuch that an axis extending between the electrodes is oriented generallyperpendicular to a flow direction of the airflow within the conduit.

These and other aspects, features and advantages of the invention willbe understood with reference to the drawing figures and detaileddescription herein, and will be realized by means of the variouselements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following brief description of the drawings anddetailed description of the invention are exemplary and explanatory ofpreferred embodiments of the invention, and are not restrictive of theinvention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of an HVAC system for delivering bipolarionization to an airflow according to an example form of the presentinvention.

FIG. 1B is a detailed view of a portion of an air handler component ofan HVAC system according to an example form of the present invention.

FIG. 2A shows a system for delivering bipolar ionization to an airflowwithin an internal combustion engine according to another example formof the present invention.

FIG. 2B is a detailed view of a filter housing portion of the system of

FIG. 2 a according to an example form of the present invention.

FIG. 3A shows an ion generator control module and mounting assemblyaccording to an example form of the present invention.

FIG. 3B shows an ion generator control module and mounting assemblyaccording to an example form of the present invention

FIG. 4 shows a bipolar ion generator mounting assembly and deliverymodule according to an example form of the present invention.

FIG. 5 shows a bipolar ion generator mounting assembly and deliverymodule according to another example form of the present invention.

FIG. 6 shows a bipolar ion generator mounting assembly and deliverymodule according to another example form of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to thefollowing detailed description of the invention taken in connection withthe accompanying drawing figures, which form a part of this disclosure.It is to be understood that this invention is not limited to thespecific devices, methods, conditions or parameters described and/orshown herein, and that the terminology used herein is for the purpose ofdescribing particular embodiments by way of example only and is notintended to be limiting of the claimed invention. Any and all patentsand other publications identified in this specification are incorporatedby reference as though fully set forth herein.

Also, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” or “approximately” one particular value and/or to“about” or “approximately” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

With reference now to the drawing figures, wherein like referencenumbers represent corresponding parts throughout the several views, FIG.1A shows an HVAC system 10 according to one example form of theinvention. In the depicted embodiment, the HVAC system is a variablerefrigerant volume (VRV) system having a shared outdoor heat exchanger12 and a plurality of individual air handler units 14, 16, 18. Inalternate forms of the invention, the HVAC system can take the form of avariable air volume (VAV), constant air volume (CAV), variablerefrigerant flow (VRF) or other forms of heating, ventilation and airconditioning system.

In typical fashion, the shared outdoor heat exchanger 12 comprises acondenser coil, compressor and fan; the individual air handler units 14,16, 18 each comprise a fan, expansion valve, heating/cooling coil(s),and a filter; and refrigerant lines connect the shared outdoor heatexchanger to the individual air handler units. Return air from theconditioned space and/or fresh air from an exterior space is treated anddelivered to a conditioned air space via the individual air handlerunits 14, 16, 18. The outdoor heat exchanger 12 discharges waste heatfrom the conditioned air space to the ambient surroundings, and/ortransfers heat from a cooled zone to a heated zone.

FIG. 1B shows internal components of an individual air handler unitaccording to an example form of the invention. An inlet airflow 30flowing through a conduit such as the housing of the air handler unit ora duct is filtered through a filter 32 such as a mesh, screen, paper,cloth or other filter media. A filtered airflow 34 downstream of thefilter 32 is treated by discharge of bipolar ionization 36 from an iongenerator 38 to form an ionized airflow 42. The bipolar ionization 36comprises a stream of negatively charged (−) ions 36 a, and a stream ofpositively charged (+) ions 36 b. The ionized airflow 42 enters theinlet of a fan or blower 44 for delivery to the treated air space, andis optionally heated or cooled by passing across or through a coolingcoil or heating element. The coil, filter 32, ion generator 38 and fan44 are optionally mounted within a housing of the air handler unit.Example modes of attachment of the ion generator include, withoutlimitation, adhesive, hook-and-loop fasteners, straps, screws, clips orother mechanical fasteners, magnetic mounting, and/or mounting bracketsor carriers affixed to or through the housing or associated ductwork.

The bipolar ion generator 38 is preferably a tubeless ion generator andcomprises at least one pair of air ionizing needlepoint electrodes 40 ⁺(positive ion generation) and 40 ⁺ (negative ion generation) such as forexample needles of stainless steel, carbon fiber, tungsten, steel orother metal; and optionally further comprising onboard controlcircuitry. The ion generator preferably produces approximately equalamounts of positive and negative ions, regardless of airflow velocity orother conditions such as humidity or temperature. U.S. Pat. No.7,177,133, hereby incorporated herein by reference, discloses an exampleform of ion generator, although it will be understood that variousdifferent ion generators may be adapted for use in connection with thepresent invention, including for example, the Sterionizer™ ion generatorsold by Filt Air Ltd. of Zikhron Yaaqov, Israel. In example forms, eachion generator 38 produces positive and negative ions in a concentrationof at least about 10⁹ ions/second, and operates on 12V DC, 110V AC, orother power source. In alternate embodiments, the ion generator(s)generate negative ions only, or positive ions only, or generate negativeand positive ions in unequal quantities. The ion generator optionallyutilizes nano-electronic components allowing the ion generator to bevery compact, requiring less than 1 watt/ion generator module, forexample less than 0.5 watts/ion module, and in further examples lessthan 0.36 watts per ion module. In example forms, the ion generatorproduces minimal or no ozone, for example at no greater concentrationthan in ambient air. Wiring may be routed through the housing forconnection to an external power source, and a power inverter may beincluded to convert the source voltage to the required input voltage ofthe ion generator. Optionally, the ion generator automatically controlsthe ion discharge output based on preset algorithms, setpoints or othercriteria, which may vary in relation to the airflow rate across theelectrodes.

The bipolar ion generator 38 is positioned and secured in place withinthe housing of the air handler unit such that the electrodes 40 ⁺ and 40⁻ are aligned generally perpendicularly to the direction of the airflow34 across the ion generator, to prevent recombination of the positivelycharged ions with the negatively charged ions. In other words, a vectorrepresenting the average flow velocity of the airflow 34 is atapproximately a right angle (90°) to an axis A extending between theelectrodes 40 ⁺ and 40 ⁻. One or more ion generator(s) 38 can beinstalled within the housing of each air handler unit, as required togenerate the desired level of ion delivery for a given airflow, as maybe determined by the airflow rate (CFM) of the fan 44 and ion dischargerate of each ion generator. The ion generator(s) are preferablypositioned generally centrally in relation to the airflow or evenlydistributed across the airflow path. If more than one ion generator isprovided in an air handler unit, they are sufficiently spaced andpositioned relative to one another to minimize recombination of positiveions with negative ions.

The system of the present invention optionally further comprises theapplication of ultraviolet (UV) light, and/or a catalyst such as forexample TiO₂ for initiating photo-catalytic oxidation, in combinationwith ion generation, for abating allergens, pathogens, odors, gases,volatile organic compounds, bacteria, virus, mold, dander, fungus, dustmites, animal and smoke odors, and/or static electricity in a treatedair space.

FIGS. 2A and 2B show another system 110 for treating and delivering airaccording to the present invention, in this embodiment comprising aninternal combustion engine 120. The system 110 includes an air intakeconduit 122 containing an intake airflow and an exhaust conduit 124containing an exhaust airflow. A filter housing 130 is positioned withinthe air intake conduit 122, and houses an air filter 132 in typicalfashion. The filter 132 comprises paper, non-woven material, or otherfilter media, and includes a series of pleats to provide an increasedsurface area for removal of particulate matter from the airflow.

One or more bipolar ion generators 140, for example as described above,are positioned within the filter housing 130, for example mounted to thehousing or retained between pleats of the filter 132, for delivery ofbipolar ionization to the intake air delivered for mixture with fuel andcombustion in the engine. The provision of a tubeless needlepointelectrode ion generator operating on 12V DC advantageously enables easeof retrofit and/or original equipment application, and connection viawiring to the electrical system of a vehicle driven by the engine 120,preferably via a fused connection. As in the above-described embodiment,the electrodes of the ion generator 140 are aligned generallyperpendicularly to the airflow to prevent ion recombination. If multipleion generators are provided, the electrodes are sufficiently spaced andpositioned to maintain the positive ion discharge unaligned with thenegative ion discharge, for example by orienting the electrodes ofdifferent ion generators facing away from one another along thedischarge side of the air filter 132. One or more brackets or mounts areoptionally provided for attachment of the system to the engine or othercombustion gas delivery component.

The treatment of air by delivery of bipolar ionization to an airflowwithin a conduit according to the systems and methods of the presentinvention may be utilized for various purposes. For example, applicationof bipolar ionization to an airflow within an HVAC conduit such as anair handler housing or duct may be utilized to abate allergens,pathogens, odors, gases, volatile organic compounds, bacteria, virus,mold, dander, fungus, dust mites, animal and smoke odors, and/or staticelectricity in a treated air space to which the airflow is directed.Ionization of air in living and working spaces may reduce buildingrelated illness and improve indoor air quality; and additionally canreduce the quantity of outside air needed to be mixed with the treatedindoor air, reducing heating and cooling costs by enabling a greaterdegree of air recirculation.

Application of bipolar ionization to an airflow conduit in automotiveapplications such as the intake to or exhaust from the engine may beutilized for removing particulates from the intake or exhaust flows,improving combustion efficiency, increasing the intake flowrate ofcombustion gas, increasing fuel mileage and/or performance, and/orreducing emissions. For example, application of bipolar ionization tothe intake air of an engine at a delivery rate of about 10⁹ ions/secondor greater may break down water (H₂O) vapor in the intake air throughelectrolysis and create elevated levels of oxygen (O₂) and hydrogen (H₂)in the air delivered to the engine for combustion. The provision ofhighly ionized intake air that is denser in O₂ and H₂ content thanincoming ambient air results in longer and/or hotter combustion of fuel,increasing cylinder pressure and creating more torque and horsepower forthe same percentage of throttle and fuel consumption. Optionally, thewater content of the intake air may be increased, for example byinjection into the intake air stream from an external source of watersuch as a remote tank or the condensate from a vehicle's airconditioner, to further enhance the generation of oxygen and hydrogen byionization.

Ionization of the engine exhaust gasses, for example via a venturi inletthat draws cool ionized air into the exhaust flow, may effectivelyeliminate the need for a catalytic converter by agglomerating unburnedcarbon particulates to prevent their becoming airborne, and bydissociating undesirable emission constituents (for example dissociatingNO_(X) into N₂ and O₂, dissociating SO_(X) into S₂ and O₂, dissociatingCO into C and O₂, etc.). In this aspect, the system and method of thepresent invention may be particularly advantageous in diesel engineapplications, as well as in gasoline engine applications and otherengine types.

Other applications within the scope of the invention may similarlyimprove combustion performance by delivery of bipolar ionization to theintake air delivered to heating boilers, gas-fired heaters, electricalpower generation boilers, water heaters, locomotives, and/or othercombustion devices. Water vapor molecules present in or added to theintake air may be dissociated by application of bipolar ionization intoH⁺, OH⁺, H⁻ and OH ions, OH, H, O, and/or HO₂.

The present invention also includes a number of ion generator carrierand mounting assemblies for application and control of delivery ofbipolar ionization to an airflow. FIGS. 3A and 3B show an exampleembodiment of an assembly 200 for mounting to the exterior of a duct,housing, or other conduit for an airflow. The assembly includes a box210 or other enclosure, such as for example a NEMA 4× enclosure orsimilar configuration, an internal panel 212 within the box, and anexternal arm 214 projecting from the back side of the box. The externalarm 214 includes mountings and electrical contacts for receiving one ormore (four are depicted) bipolar ion generators 220 for delivery ofbipolar ionization to an airflow within the conduit. The mountingssecurely engage the ion generators 220 and maintain them in anorientation having their electrodes axially aligned with the arm 214 andgenerally perpendicular to the airflow. The panel 212 optionallycomprises one or more pluggable terminal blocks for wiring connection tothe ion generators via the contacts on the arm 214, a connection forpower input, and one or more indicators such as LEDs to indicate thepresence/absence and operational state (on/off, ion output, etc.) of theion generators. Optionally, a power converter or transformer is providedin the box 210 for converting the input power to the power required tooperate the ion generators. One or more connectors are optionallyprovided for mounting the box 210 to the exterior of a duct or housing,with the arm 214 extending into the duct or housing through an openingformed therein. Sealing means such as a gasket are optionally providedon the back of the box 210 around the arm 214 for sealing around theopening. FIG. 4 shows an assembly 300 according to an alternateembodiment, having a reclosable box 310 with an arm 314 extendingtherefrom, and otherwise being substantially similar to assembly 200.The length of the arm 214 may vary depending on the size of the conduitit is to be applied to and the number of ion generators to be installed,and in example embodiments is between 2″-24″, for example about 10″ inlength.

FIG. 5 show another embodiment of an ion generator mounting assembly 400according to the present invention. The assembly 400 includes anexternal power supply 410 for mounting external of the duct, housing orother conduit; and one or more ion generators 412 for mounting internalof the conduit for delivery of bipolar ionization to an airflow withinthe conduit. Wires 414 extending between the external power supply 410and the ion generators 412 pass through an opening in the wall of theconduit to deliver power from the power supply to the ion generators.The external power supply 410 optionally comprises control circuitryand/or indicators for displaying the operational state of the iongenerators.

FIG. 6 shows another embodiment of an ion generator mounting assembly500 according to the present invention. The assembly 500 includes acontrol panel 510 for mounting external of the duct, housing or otherconduit, and an internal rack 512 for mounting in the conduit'sinterior. The rack 512 includes electrical couplings and mountingreceivers for receiving at least one, and preferably a plurality of iongenerators for delivery of bipolar ionization to an airflow within theconduit.

While the invention has been described with reference to preferred andexample embodiments, it will be understood by those skilled in the artthat a variety of modifications, additions and deletions are within thescope of the invention, as defined by the following claims.

What is claimed is:
 1. A system for treatment of an airflow within aconduit, the system comprising at least one bipolar ion generator havingfirst and second electrodes, the first electrode generating positiveions and the second electrode generating negative ions, wherein thefirst and second electrodes are aligned generally perpendicular to theairflow within the conduit whereby at least a portion of the positiveions and the negative ions do not recombine within the airflow. 2-3.(canceled)
 4. The system of claim 1, wherein the at least one bipolarion generator is a tubeless ion generator, and wherein the first andsecond electrodes are needlepoint electrodes.
 5. The system of claim 1,wherein the conduit is an HVAC duct.
 6. The system of claim 1, whereinthe conduit is an air handler unit housing of a VRV or VRF HVAC system.7. The system of claim 6, comprising a plurality of air handler unithousings connected to a shared outdoor heat exchanger, each of theplurality of air handler unit housings having at least one bipolar iongenerator delivering positive and negative ions to an airflow therein.8. The system of claim 1, wherein the at least one bipolar ion generatoris mounted to an assembly, the assembly having an interior portionpositioned within the conduit and an exterior portion positioned outsidethe conduit.
 9. (canceled)
 10. A combustion system comprising: acombustion air intake for delivering combustion air along a flowpath;and at least one bipolar ion generator for delivering positive andnegative ions into the combustion air, each said at least one bipolarion generator having positive and negative electrodes, the positive andnegative electrodes being aligned generally crosswise relative to theflowpath of the combustion air.
 11. (canceled)
 12. The combustion systemof claim 10, wherein each said at least one bipolar ion generatorcomprises a tubeless ion generator.
 13. The combustion system of claim10, further comprising an air filter housing having an air filtertherein, and wherein the at least one bipolar ion generator is mountedwithin the air filter housing.
 14. The combustion system of claim 13,wherein the at least one bipolar ion generator is positioned withinpleats of the air filter. 15-25. (canceled)